An exterior wall and a method for constructing an exterior wall

ABSTRACT

Disclosed is an exterior wall ( 17 ) for a building ( 11 ). The exterior wall ( 17 ) comprises an inner wall ( 20 ) including a load-bearing structure formed by a transversal roof metal profile ( 14 ) and a transversal foundation metal profile ( 13 ) between which a number of intermediate metal profiles ( 15 ) extend, and wherein an inside surface ( 59 ) of the inner wall ( 20 ) is provided inner sheathing ( 63 ). The exterior wall ( 17 ) also comprises an outer wall ( 21 ) including a load-bearing structure formed by a transversal roof metal profile ( 14 ) and a transversal foundation metal profile ( 13 ) between which a number of intermediate metal profiles ( 15 ) extend, and wherein an outside surface ( 64 ) of the outer wall ( 21 ) is provided outer sheathing ( 62 ). The inner wall ( 20 ) and the outer wall ( 21 ) are mutually fixed at the transversal metal roof profiles ( 13 ) and the transversal metal foundation profiles( 14 ) so that a cavity ( 34 ) is formed between the inner wall ( 20 ) and the outer wall ( 21 ). A method for constructing an exterior wall ( 17 ) of a building ( 11 ) is also disclosed.

FIELD OF THE INVENTION

The invention relates to an exterior wall construction for a building,wherein the exterior wall comprises an inner wall and an outer wall.

The invention also relates to a method for constructing an exterior wallconstruction of a building.

The present invention further relates to a system for construction of abuilding which is erected on a foundation and which comprises atransversal roof metal profile, a transversal foundation metal profileand intermediate metal profiles, horizontal profiles and a roofstructure.

BACKGROUND OF THE INVENTION

A building is normally erected by constructing an insulated foundationand subsequently placing walls on the foundation before a roof structureof the building is formed so that it is carried by at least someexternal walls.

The external walls of a building normally comprise an inner brick walland an outer brick wall. The outer wall is the outside of the buildingand constitutes the building envelope of the building, and the innerwall is placed against the inside of the building. Between the innerwall and the outer wall, there is a cavity filled with insulationmaterial.

This traditional construction method is time-consuming and the walls arethick, heavy and expensive.

OBJECT OF THE INVENTION

It is the object of the invention to provide for an advantageoustechnique for constructing exterior walls for a building.

DESCRIPTION OF THE INVENTION

The invention relates to an exterior wall construction for a building.The exterior wall comprises an inner wall including a load-bearingstructure formed by a transversal roof metal profile and a transversalfoundation metal profile between which a number of intermediate metalprofiles extend, and wherein an inside surface of the inner wall isprovided with inner sheathing. The exterior wall also comprises an outerwall including a load-bearing structure formed by a transversal roofmetal profile and a transversal foundation metal profile between which anumber of intermediate metal profiles extend, and wherein an outsidesurface of the outer wall is provided with outer sheathing. The innerwall and the outer wall are mutually fixed at the transversal metal roofprofiles and the transversal metal foundation profiles so that a cavityis formed between the inner wall and the outer wall.

Forming the load-bearing structure of both the inner wall and the outerwall from metal profiles is advantageous in that it enables that bothwalls easily can transported around and be assembled in situ. Thisreduces the transportation cost and ensures a fast in situ assembly. Andproviding the inner wall with inner sheathing and the outer wall withouter sheathing is advantageous in that it hereby is possible to form aclosed space inside the wall hereby lowering the thermal conductivity ofthe wall, and as the same time increasing the soundproof quality of thewall and protecting the inside of the house better.

One big drawback with forming the walls from metal profiles is thatmetal typically is an excellent thermal conductor and the risk ofunwanted conducting of heat in or out of the building is thereforeincreased. However, air is a pour thermal conductor and by forming acavity between the inner wall and the outer wall so that the two wallsare only mutually connected at the transversal metal roof profiles andthe transversal metal foundation profiles ensures that such a wall has avery low thermal conductivity—particularly in light of its weight, costand thickness.

In an aspect of the invention, the inner sheathing and/or the outersheathing comprises a vapour barrier.

Forming a vapour barrier on the inside surface of the inner wall isadvantageous in that the risk of moisture build-up or condensing insidethe wall construction is reduced.

In an aspect of the invention, the inner sheathing and/or the outersheathing comprises a fire-resistant layer.

Providing the inside surface of the inner wall and/or the outer surfaceof the outer wall with a fire-resistant layer—such as gypsum boards,metal sheets, slate, concrete plates or other—is advantageous in that itreduces the risk of fire spreading and reduces the damage of a fire.

In an aspect of the invention, the outer sheathing comprises façadecladding.

Providing the outer surface of the outer wall with façade cladding isadvantageous in that it hereby is possible to provide the outside of thewall with desired qualities and look.

In an aspect of the invention, the metal profiles are interconnected byconnection means.

Interconnecting the metal profiles by means of connection means—such asscrews, nails, rivets, welding, adhesive, interlocking geometry orother—is advantageous in that it ensures simple assembly and a morerigid structure.

In an aspect of the invention, the metal is steel.

Steel is strong in relation to its weight—particularly if it is in theform of profiled sheet metal—, it is easy to machine and it isrelatively inexpensive.

In an aspect of the invention, thermal insulation means is arrangedinside the cavity.

Further arranging thermal insulation means inside the cavity isadvantageous in that it reduces the thermal conductivity through theexterior wall.

In an aspect of the invention, thermal insulation means is arrangedbetween the metal profiles of the inner wall and between the metalprofiles of the outer wall.

Further arranging thermal insulation means between the metal profiles ofthe inner wall and between the metal profiles of the outer wall isadvantageous in that it reduces the thermal conductivity through theexterior wall.

In an aspect of the invention, each metal profile of the inner wall andthe outer wall comprise identification means enabling that each uniquemetal profile can be uniquely identified.

Enabling unique identification of each unique metal profile isadvantageous in that it hereby is possible to deliver the wall as anassembly kit in that the wall hereby easily can be assembled in situaccording to a premade plan in which the assembly order and the specificplacement of the specific metal profiles is laid out. There is thereforeno need to measure the profiles as they can easily be identified fromtheir identification means.

The term “identification means” is in this context to be understood asany kind of label, tag, inscription, marking, embossing, stamping, RFIDtag, EPROM (Erasable Programmable Read Only Memory) or any other kind ofmanual or electrical means capable of holding information regarding thespecific profile type.

In an aspect of the invention, the metal profiles are U-profiles.

Forming the metal profiles as U-profiles is advantageous in that aU-profile is strong, rigid and easy to manufacture.

In an aspect of the invention, a majority of the intermediate metalprofiles of the inner wall is displaced in relation to a majority of theintermediate metal profiles of the outer wall as seen in a directionperpendicular to the inner wall.

After the wall has been assembled the wall will most likely be filledwith insulation material. And to ensure that this material gets into allnooks and corners of the inside of the wall this insulation materialcould advantageous be blown-in granular insulation material such asshredded paper, Lightweight expanded clay aggregate (LECA), Styrofoambeads or similar insulation material suited for being injected into theinside of a metal profile cavity wall structure.

In an aspect of the invention, the transversal roof metal profile of theinner wall is parallel with the transversal roof metal profile of theouter wall and wherein the transversal foundation metal profile of theinner wall is parallel with the transversal foundation metal profile ofthe outer wall.

Forming the roof and foundation profiles parallel is advantageous inthat it provides for parallel inner and outer walls and thus a constantthickness of the exterior wall.

In an aspect of the invention, the transversal roof metal profile of theinner wall is parallel with the transversal foundation metal profile ofthe inner wall and wherein the transversal roof metal profile of theouter wall is parallel with the transversal foundation metal profile ofthe outer wall.

Forming the roof and foundation profiles parallel in each wall isadvantageous in that ensures flush wall that are easier to install.

In an aspect of the invention, the intermediate metal profiles extendsperpendicular in relation to the transversal roof metal profiles and thetransversal foundation metal profiles.

Forming the intermediate metal profiles perpendicular to the transversalroof metal profiles and the transversal foundation metal profiles isadvantageous in that the intermediate profiles hereby will besubstantially vertical in the finished erected wall—which in turn willensure that the intermediate metal profiles will be able to carry moreweight of the superjacent roof structure or superjacent floor/storey.

The invention also relates to a method for constructing an exterior wallconstruction of a building. The method comprises the steps of:

-   -   assembling a number of prefabricated metal profiles according to        a predefined plan to form an inner wall of the exterior wall        construction of the building,    -   assembling a number of prefabricated metal profiles according to        a predefined plan to form an outer wall of the exterior wall        construction of the building,    -   mutually fixing the inner wall and the outer wall in relation to        each other at a foundation of the building and at a roof of the        building so that a cavity is formed between the inner wall and        the outer wall.

Forming the exterior wall from metal profiles ensures a strong, thin andinexpensive wall which easily and quickly can be assembled on site bymeans of a premade assembly instruction in that such a wall can be madeof relatively few profiles—due to the double hull wall design. And byforming the inner and outer wall so that they in respect to thermalconductivity substantially is only connected at the foundation of thebuilding and at the roof of the building—hereby forming an substantiallycontinuous cavity between the inner and outer wall—is advantageous inthat thermal condition through the exterior wall hereby is reduced evenif metal is an excellent thermal conductor.

In an aspect of the invention, the method further comprises the step ofsubstantially covering an inside surface of the inner wall with an innersheathing.

Providing an inner sheathing to the inside surface of the innerwall—i.e. the surface facing into the building—is advantageous in thatit can aid in providing rigidity to the wall structure, it can act as avapour barrier and/or a fire-resistant layer and it can act as a barrierfor insulating material in the wall.

In an aspect of the invention, the method further comprises the step ofsubstantially covering an outside surface of the outer wall with anouter sheathing.

Providing an outer sheathing to the outside surface of the outerwall—i.e. the surface facing away the building—is advantageous in thatit can aid in providing rigidity to the wall structure, it can act as avapour barrier and/or a fire-resistant layer and it can act as a barrierfor insulating material in the wall as well as giving the building thedesired façade look etc.

In an aspect of the invention, the method further comprises the step ofarranging thermal insulation means inside the cavity.

Arranging thermal insulation means inside the cavity after the inner andouter walls have been erected and fixed is advantageous in that thiswill further reduce thermal conductivity of the wall.

In an aspect of the invention, the method further comprises the step ofarranging thermal insulation means between the metal profiles of theinner wall and between the metal profiles of the outer wall.

Arranging thermal insulation means between the metal profiles of theinner wall and between the metal profiles of the outer wall after theinner and outer walls have been erected and fixed is advantageous inthat this will further reduce thermal conductivity of the wall.

In an aspect of the invention, the method further comprises the step ofproviding identification means to metal profiles.

Different metal profiles could be uniquely identified by measuring them,visually inspecting their design or in other ways detecting how they aredifferent from other metal profiles. But this is difficult and timeconsuming and it is therefore much more efficient to provide the metalprofiles with identification means before the wall is to be assembled sothat the onsite assembly time is reduced.

In an aspect of the invention, the method is a method for constructingan exterior wall construction according to any of the previouslymentioned exterior walls.

The present invention also relates to using a system of the typeinitially mentioned, distinctive in that

-   -   the transversal roof metal profile and the transversal        foundation metal profile comprise a first guide profile for an        inner wall and a first guide profile for an outer wall in a wall        structure as well as a spacing element located between these        first guide profiles, which first guide profile comprises an        angle profile having a horizontal flange in use and a vertical        flange in use, wherein in the horizontal flange with a        predefined mutual distance, first tabs are provided which are        folded so as to be located under an angle in relation to the        horizontal flange, and which each comprise a hole,    -   the transversal foundation metal profile can act as a wall plate        in a floor separation or a wall plate to support the roof        structure,    -   each post comprises a intermediate metal profile located between        the first guide profiles in the inner wall or the outer wall at        a position in line with the first tabs, which intermediate metal        profile comprises two opposite flanges located in parallel        planes, which are mutually connected by a central flange,        wherein at each end of the central flange of the intermediate        metal profile, a second tab is provided, which is resilient in        relation to the central flange, and which are each adapted for        resilient engagement in the hole in the first tab,    -   each horizontal profile comprises a mounting guide profile which        comprises two opposite flanges located in parallel planes, which        are mutually connected by a central flange, the first of the        opposite flanges being adapted for mounting on the posts, and        the second of the opposite flanges being adapted for mounting of        inner cladding or facade cladding of the inner wall,        respectively the outer wall, and    -   the roof structure comprises a lattice girder formed by two        opposite fourth guide profiles, between which fifth guide        profiles are mounted to form the lattice structure. The        invention thus makes it possible to use pre-fabricated guide        profiles. Such guide profiles may be manufactured from metal        profiles. The metal profiles are preferably a combination of        steel profiles and aluminium profiles.

The profiles are manufactured in advance and in well-defined lengths,depending on the size of the building to be made. Long profiles may becomposed of several profile units, e.g. to form a sufficient length oftransversal roof metal profile and transversal foundation metal profile.

As the guide profiles may be formed in advance, it is also possible topack these in sets containing the number and the combination of guideprofiles to be used for a building in question.

Using the system according to the invention achieves a certainty ofcorrect assembly without a need for special workman skills.

As the guide profiles are provided with connecting means used forcoupling of guide profiles, a predefined placing of the connecting meanswill ensure that correct mutual connection of the guide profiles alsotakes place.

Intermediate metal profiles placed between a transversal roof metalprofile and transversal foundation metal profile will thus be placed andfixed in connection with tabs on transversal roof metal profile andtransversal foundation metal profile. Hereby, the position of posts isdetermined, and the distance between transversal roof metal profile andtransversal foundation metal profile will likewise be determined fromthe length of the posts.

As the posts are provided with a resilient tab that can engage with thehole in the first tab on transversal roof metal profile and transversalfoundation metal profile, a very quick and simple assembly of theseelements will be achieved.

The coupling elements are normally designed for temporary retention ofthe elements during mounting and will therefore be supplemented by anailing together or other fixed coupling of the elements in the finishedbuilding.

Is is thus common for the resilient engagement between a tab and hole tobe combined with a nailing together or other form of fixing. However, itmay turn out that several assemblies do not require supplementing by thefixed coupling. The erection will thus be able to take place veryquickly, and the mutual connections between guide profiles will have astrength defined in advance on the basis of the design of the resilienttabs.

When a structure has been made with a transversal roof metal profile andtransversal foundation metal profile and posts located there between,horizontal profiles in the form of the mounting guide profile can beplaced on the outside of the intermediate metal profiles. These mountingguide profiles can be used on the inside as well as the outside of thehouse to mount inner cladding or facade cladding. A building accordingto the invention will thus be made with inner wall and outer wall. Inthe cavity between inner wall and outer wall, insulation can be placed,and wiring and cables for the installations in the building can also beducted here.

The roof structure may be a pitched roof or a flat roof. It may also bea flat roof with a unilateral slope. For the use of the roof structure,a lattice girder is used, which is also formed by guide profiles. Inorder to join the guide profiles, fifth guide profiles are provided,which are mounted jointly around the lattice girder.

If it is a pitched roof, this principle can be used in the joining ofthe lattice beams at the top of the roof structure. Here, opposite guideprofiles will be used, which are mounted jointly around the latticebeams from each side of the roof structure.

The fifth guide profiles can be said to work according to the sameprinciple as studding or book ends.

A pole plate can be formed by a folded plate mounted on the transversalfoundation metal profile, and which is also fixed to the lattice beams.The pole plate may also be formed by two opposite guide profiles.

If it is a pitched roof, a similar principle can be used when joiningthe lattice beams at the top of the roof structure. Here, opposite guideprofiles will also be used, which are mounted jointly around the latticebeams from each side of the roof structure.

The guide profiles used for joining around the lattice beams can bejoined using nailing, riveting or in some other way. Likewise, theseguide profiles for joining around the lattice beams could be joinedusing resilient tabs that cooperate with holes corresponding to theconnecting means used between transversal roof metal profile andtransversal foundation metal profile and the posts.

The horizontal profiles mounted on the intermediate metal profiles maybe mounted in predefined positions, as the intermediate metal profilesmay be provided with connecting means placed with predetermined cavitysand which are adapted to cooperate with corresponding connecting meanson the horizontal profiles.

A very uniform placing of the horizontal profiles can thus be achievedand consequently also the facade cladding or inner cladding which ismounted subsequently.

According to a further embodiment, the system according to the inventionis distinctive in that posts in the inner wall and the outer wall aredisplaced in relation to each other, and that the posts are preferablymounted in every second of the first tabs in the first guide profiles.

With this embodiment thermal bridges are avoided in the wall structure.As there is a cavity between the inner wall and the outer wall, and asposts located in the cavity between the inner wall and the outer wallare displaced from each other, the risk of a thermal bridge is reduced.

It is preferred that transversal roof metal profile and transversalfoundation metal profile are manufactured identically. To this end,first tabs are provided having a distance corresponding to the distancebetween two subsequent posts located in inner wall and outer wall,respectively. The posts will thus only need to be placed in every secondof the first tabs.

Alternatively, a longer distance may have been provided between thetabs, corresponding to the distance between the posts in the inner walland the distance between the posts in the outer wall. This is merely toensure that transversal roof metal profile and transversal foundationmetal profile are placed in such a way that the first tabs in guideprofile for the inner wall are continued in relation to the tabs in thefirst guide profile for the outer wall.

According to a further embodiment, the system according to the inventionis distinctive in that the first tab is formed by a punched part of thehorizontal flange, and that the first tab is connected to the horizontalflange along a folding line and is folded to a position perpendicular tothe horizontal flange. By forming the tab as a punched part of thehorizontal flange, a particularly appropriate manufacture is achieved.Materials savings are thus achieved while avoiding the need for loosetabs that need to be connected with the first guide profile. The firsttab is folded around a folding line in the horizontal flange, so that itis perpendicular to the horizontal flange. This makes the tabs facedownwards, depending on whether the first guide profile is used for thetransversal roof metal profile or for the transversal foundation metalprofile.

According to a further embodiment, the system according to the inventionis distinctive in that the hole in the first tab is a rectangular hole.The hole being rectangular achieves a safe engagement with a tab whichalso has a rectangular shape. This achieves a positioning in the lateraldirection by sizing the tab so that it has a width that fits into thewidth of the rectangular hole.

According to a further embodiment, the system according to the inventionis distinctive in that the second tab in the intermediate metal profileis S-shaped and adapted to engage with the hole in a first tab. AnS-shape on the first tab achieves a resilient effect in a particularlysimple way. When the S-shape is folded partly out of the plane from theflange, it will be possible to fold it to such a position that itestablishes a larger or smaller resilient force and thus safeengagement.

According to a further embodiment, the system according to the inventionis distinctive in that the second tab is formed by a punched part of thecentral flange of the intermediate metal profile, and that the secondtab is connected to the central flange along a folding line and isfolded to an outside position on the central flange. At the secondprofile, the most important condition is that two opposite flanges areplaced. The profile may thus have different profile shapes, as theflange element connecting the two different flanges may be placedcentrally, askew or at one side.

According to a further embodiment, the system according to the inventionis distinctive in that the second profile is a U-, H- or Z-shapedprofile. It is merely important that two opposite flanges areestablished.

According to a further embodiment, the system according to the inventionis distinctive in that the lattice girder is mounted to the transversalfoundation metal profile via a pole plate comprising two opposite fifthguide profiles. In the roof structure, the above pole plate is used forfixing the lattice girder to the transversal foundation metal profile.As two opposite fifth guide profiles are used, the pole plate can alsobe manufactured in advance.

The pole plate may be joined around the lattice girder in advance orjoined on-site, depending on what is more appropriate. By joining thetwo opposite guide profiles of the pole plate around the lattice girderon-site, there is a smaller space requirement when transporting thelattice beams compared to lattice girders which are premounted forforming the roof profile.

In a pitched roof, opposite guide profiles are also used for the mutualconnection of the two lattice girders at the top where two latticegirders abut each other.

According to a further embodiment, the system according to the inventionis distinctive in that the two opposite flanges of the intermediatemetal profile comprise connecting means provided with a predefinedmutual distance for cooperating with corresponding connecting means onthe mounting guide profile.

As the intermediate metal profile used for the posts is provided withconnecting means having a predefined mutual distance, it is possible toplace the horizontal profiles with the distance corresponding to themutual distance between the connecting means, or alternatively byplacing the horizontal profiles between every second or third connectionmeans in a intermediate metal profile.

This ensures correct mounting of the horizontal profiles. The connectingmeans used between the horizontal profiles and the intermediate metalprofiles can be of the type described in a pending patent applicationsubmitted by the same inventor as the present invention.

The mounting guide profile used for the horizontal profiles, at theoutside facing away from the wall structure, is provided with connectingmeans to which cladding elements for an external or internal facade canbe mounted.

According to a further embodiment, the system according to the inventionis distinctive in that a first angle bracket is fixed to posts forfixing of horizontal frame profiles for mounting of windows and doors inthe wall structure, the first angle bracket comprising coupling meansthat cooperate with corresponding coupling means at the end of thehorizontal frame profile.

As windows and doors often require special frames, it is advantageousfor the posts to have angle brackets. To this end, horizontal frameprofiles may be fixed, which are used at the top or bottom of a windowor a door. This first angle bracket has coupling means which cooperatewith corresponding coupling means at the end of the horizontal frameprofile.

It is preferred that the horizontal frame profiles are identical to theintermediate metal profile. The profiles can thus be provided with holescorresponding to the holes in the second tab on the intermediate metalprofile. To this end, the first angle bracket will advantageously bemanufactured with resilient tabs designed for engagement with the holeson the horizontal frame profiles.

A reverse design, wherein the tabs are a part of the horizontal frameprofiles and the holes are provided on the angle brackets, is alsopossible.

Although it is easy to have the resilient tabs placed on a centralflange, it will also be possible to place the resilient tabs on two sideflanges in a U-shaped profile. In this way, a coupling can be achievedof greater strength, as more tabs can be used for the coupling of guideprofiles, regardless whether it is the first, second or mounting guideprofile.

According to a further embodiment, the system according to the inventionis distinctive in that between two horizontal frame profiles, at leastone vertical frame profile for mounting of windows and doors is mounted,which has a smaller width than the distance between two posts in thewall structure, and in that on a horizontal frame profile, a secondangle bracket for fixing of the vertical frame profile is mounted, thesecond angle bracket comprising coupling means that cooperate withcorresponding coupling means at the end of the vertical frame profile.

In order to be able to mount windows or doors having a smaller widththan the distance between two subsequent posts in the wall structure, atleast one vertical frame profile is placed between two horizontal frameprofiles located above each other.

Alternatively, a vertical frame profile can also be placed between ahorizontal frame profile and a transversal roof metal profile or atransversal foundation metal profile. This depends on where the buildingopening is placed. On the second frame profile, a second angle bracketis mounted, to which the vertical frame profile can be fixed. The secondangle bracket will preferably be designed with a C-shape or hook shape,so that it can be swung over the horizontal frame profiles and bedisplaced along these. In this way, it becomes possible to adjust thesize of the wall opening formed in the wall structure. The second anglebracket comprises coupling means which cooperate with correspondingcoupling means in the vertical frame profiles.

According to a further embodiment, the system according to the inventionis distinctive in that the second angle bracket is U-shaped in order tobe able to be swung over the horizontal frame profile and to be able tobe displaced along this to a desired position in relation to thevertical frame profile, and in that it comprises a third tab which isfolded so as to be located under an angle in relation to the horizontalframe profile, and which comprises the coupling means.

As mentioned, the displacement will enable a more flexible size of thebuilding opening that can be formed in the wall structure.

If the displaceable horizontal frame profile is designed with a tabwhich is folded so as to be located under an angle in relation to thehorizontal frame profile while at the same time comprising couplingmeans in the form of a hole, it will likewise be possible to establishthe joint between the horizontal frame profiles and the vertical frameprofiles by using the resilient tab already mentioned in connection withthe other guide profiles.

A system according to the invention thus makes it possible to establisha very simple system, wherein the coupling of different elements cantake place using similar or completely identical elements.

It is also possible that both vertical and horizontal frame profiles canbe identical and that these vertical and horizontal frame profiles canbe identical to the dividing profiles used for posts and/or for thetransversal roof metal profiles and transversal foundation metalprofiles of the wall structure.

It will thus be very simple to manufacture the guide profiles for thebuilding structure.

It is preferred that guide profiles for transversal roof metal profileand transversal foundation metal profile are constituted by steelprofiles.

In the system according to the invention, it is possible that betweenthe horizontal profiles, mounting profiles are placed which arepre-fabricated and which are used for the mounting of e.g. socketoutlets. Such socket outlet profiles may be manufactured with punchedholes and may be provided with profiles, in which connecting means inthe form of tabs are provided, which can be folded around the flanges ofthe horizontal profiles, so that the use of tools can be avoided here aswell when mounting the socket outlet profiles.

When constructing the roof structure, a sixth guide profile can be usedto form struts/battens.

By manufacturing such sixth guide profiles with mutual well-definedopenings, wherein the lattice beams can be received, theserafters/struts may be used to ensure correct mutual positioning of thelattice girders of the roof structure.

It should be noted that the lattice beams can be mounted in a pole platein such a way that they are extended beyond the pole plate, whereby anoverhang for the building can be formed. At the outer end of theopposite fourth guide profiles of the lattice beams, a connectionprofile will be provided, which offers the possibility to mountdifferent facade elements, fascia boards and similar on the overhang.

It should be noted that the lattice beams used in the roof structure canalso be used as a floor structure. Lattice girders can thus be placedunder a floor in the building structure and thereby form a cavity fordrainage installations for sewers similar.

The floor structure can be provided by lattice girders being placedwithin foundation blocks on which the transversal roof metal profile isplaced. The structure may be manufactured so that a crawl space isestablished under the lattice beams or in such a way that the latticebeams are laid on a poured foundation.

In an aspect of the invention the system is a system for construction ofa building comprising exterior walls according to any of the previouslydescribed exterior walls.

DESCRIPTION OF THE DRAWINGS

In the following, the invention will be described in detail withreference to the accompanying drawings, where

FIG. 1 shows a principle design of a building in which a systemaccording to the present invention is used,

FIG. 2 shows a detail in the design of the foundation and a transversalfoundation metal profile in the building shown in FIG. 1,

FIG. 3 shows an enlarged image of the design shown in FIG. 2,

FIG. 4 shows a principle sketch of a wall having an inner wall and anouter wall each comprising a transversal foundation metal profile,

FIG. 5 shows a detail of the mounting of a post on a transversalfoundation metal profile,

FIG. 6 shows an enlarged image in partial cross-section through theconnection shown in FIG. 5,

FIG. 7 shows a principle sketch for mounting of inner cladding on a wallstructure,

FIG. 8 shows a detail in the construction of the inner wall cladding,

FIG. 9 shows a detail of the mounting of a socket outlet profile in aninner wall,

FIG. 10 shows an enlarged image of the socket outlet profile shown inFIG. 9,

FIG. 11 shows a detail of the mounting of the socket outlet profileshown in FIGS. 9 and 10,

FIG. 12 shows a principle sketch for formation of an opening formounting of a window in the wall structure, constructed using a systemaccording to the invention,

FIG. 13 shows details of the structure shown in FIG. 12,

FIGS. 14 and 15 show further details of the mounting of the frameprofiles shown in FIGS. 12 and 13,

FIG. 16 shows an image of a pole plate used for mounting a latticegirder on the transversal roof metal profile,

FIGS. 17 and 18 show details of the joining of two lattice girders toeach other in a pitched roof structure,

FIG. 19 shows how the lattice girders of the roof structure are mutuallyconnected using a sixth guide profile,

FIG. 20 shows the sixth guide profile used in FIG. 19,

FIG. 21 shows the termination of a lattice girder at a roof overhang,

FIG. 22 shows a second embodiment for a building having unilateral roofslope, and wherein a system according to the invention is used,

FIGS. 23-25 show different guide profiles forming part of a systemaccording to the invention, and

FIG. 26 discloses a wall section wherein the metal profiles compriseidentification means.

DETAILED DESCRIPTION OF THE INVENTION

In the following, the invention will be described in more detail withreference to different figures, wherein identical or similar elementshave the same reference designation. All structure elements will thusnot be explained in detail in connection with each figure.

FIG. 1 shows a building 11 erected on a foundation 12. The buildingcomprises a transversal roof metal profile 14, a transversal foundationmetal profile 13 and intermediate metal profiles 15 placed between thetransversal roof metal profile 14 and the transversal foundation metalprofile 13. The building also comprises horizontal profiles 16. Theseelements 13, 14, 15, 16 are used for the load-bearing structures of theexterior wall structure 17 of the building. In this embodiment theload-bearing structure is the structure carrying the superjacent roofstructure 18 but in another embodiment it could also or instead beanother floor or other.

In this embodiment the building 11 further comprises a roof structure18.

In the building 11 shown, a window opening 19 is furthermore defined.

FIGS. 2 and 3 contain a more detailed figure of the construction of thefoundation 12. In this embodiment the foundation is composed offoundation blocks 4. These are preferably provided with an EPS core.Between the outer and inner foundation blocks 4, an insulation 3 isplaced. This is preferably EPS (expanded polystyrene).

Above the foundation, a vapour seal 2 is placed. This is preferably anEPDM rubber membrane. It preferably has a thickness of 5 mm.

This vapour seal can be used for levelling any unevenness fortransversal roof metal profile 14 placed on top.

The transversal foundation metal profile 13 comprises a guide profile 1,provided in the form of an L-shaped steel profile. A first guide profile1 is provided at the bottom end of an inner wall 20 and at an outer wall21.

Between the two first guide profiles 1, a distance profile 22 isprovided. The distance profile 22 ensures the correct mutual placing ofthe two first guide profiles 1, so that a well-defined thickness of thewall structure 17 and the cavity 34 between the inner wall 20 and outerwall 21 is thus achieved. However in another embodiment the inner wall20 and/or outer wall 21 could be connected more or less directly (e.g.through some thermal insulating pad or material) to the roof structure18 and/or the foundation 12—i.e. without a distance profile 22—or thedistance profile 22 could be attached to the inner wall 20 and/or outerwall 21 by means of connection means such as screws, rivets, adhesive orother.

As can be seen from FIGS. 2 and 3, the outside surface 64 of the outerwall 21 is provided with outer sheathing 62 which in this embodimentcomprises façade cladding 5. The facade cladding 5 can be shale, slate,painted aluminium, facade stone, fibre cement and other facade claddingsthat may be desirable for use.

In the design shown, a powerboard 7 has been used as facade cladding 5.

The facade cladding 5 is mounted on a mounting guide profile 6. Thisguide profile is Z-shaped and preferably manufactured from salt waterresistant aluminium. This mounting guide profile 6 is mounted on gypsumboards connected to the intermediate metal profiles 15 of the outer wall21. In this embodiment the gypsum boards will act as a fire-resistantlayer 23.

FIG. 4 shows more clearly how the outside surface 64 of the outer wall21 is provided with a fire-resistant layer 23. In another embodimentalso the inside surface 59 of the inner wall 20 would be provided withfire-resistant layer 23.

In this embodiment the transversal foundation metal profile 14 is formedas an L-shaped profile having a vertical flange 25 and a horizontalflange 26. The tabs are folded along a folding line 47 from thehorizontal flange 26. The tabs are used, as explained in the following,for mounting of intermediate metal profiles 15.

FIGS. 5 and 6 show more clearly how a tab 24 is folded out of the planeof the horizontal flange 26. The tab 24 is provided with a hole 27. Thehole 27 serves to receive a resiliently springy tab 28 in theintermediate metal profiles 15.

The intermediate metal profiles 15 comprises two opposite flanges 29,30, which are mutually connected by a central flange 31, so that aU-shaped profile is formed. The tab 28 is punched and pressed out fromthe central flange 31.

The tab 28 has an S-shaped configuration, so that a central part 32 ofthe tab in a resilient way is pressed into the hole 27 when theintermediate metal profile 15 is pressed down into abutment with thefirst guide profile 1. Hereby, a mutual retention and a correctpositioning of the two guide profiles is established. This mutualretention establishes a safe fixing during mounting of the building.Subsequently, the two guide profiles will be fixed permanently to eachother, e.g. by nailing using a gas-powered gun or by riveting or byother appropriate permanent connections between the two guide profiles.

However, in another embodiment the metal profiles 13, 14, 15, 16 couldinstead or also be connect by means of connection means 65 such asscrews, rivets, adhesive or other from the start so that the describedtap system could be avoided.

FIGS. 7 and 8 show a mounting of an inner wall 20. In this embodimentthe inner wall 20 comprises the gypsum boards will act as afire-resistant layer 23. FIG. 7 also shows a vapour seal 10 which ismounted on the outside of insulation 33 in the cavity 34 between theinner wall 20 and the outer wall 21. However, in a preferred embodimentthe vapour barrier 10 would be placed on the inside surface 59 of theinner wall 20.

The inner wall 20 is in this embodiment provided with horizontalmounting guide profiles 6 corresponding to mounting guide profiles 6used for the cladding of the outside surface 64 of the outer wall 21.

Regardless whether the issue is cladding of the external wall or theinner wall, the mounting guide profiles 6 can be a Z-shaped profilehaving a flange in abutment with the intermediate metal profiles 15 andthe inner sheathing 63 and/or the outer sheathing 62. However, inanother embodiment the mounting guide profiles 6 would be designeddifferently or the would not be present at all, so that the innersheathing 63 and/or the outer sheathing 62 would be mounted directly onthe inner wall 20 and the outer wall 21.

As can be seen from FIG. 8, there is a gap 67 between the back side ofthe fire-resistant layer 23 and the insulation 33. This gap 67 isdesigned for ducting of cables and pipes. All ducting work can thus beperformed on the inner side of the vapour seal 10 which is mounted onthe insulation 33. There is thus no risk of penetration of the vapourseal.

As is apparent from the above, and as can be seen in particular fromFIG. 4, the intermediate metal profiles 15 are located displaced fromeach other in the inner wall and the outer wall. This minimises the riskof thermal bridges through the wall structure and ensures a more evendistribution of injected insulation material.

FIGS. 9-11 show certain special conditions around the mounting of asocket outlet profile 35. The socket outlet profile 35 is mountedbetween a mounting guide profile 6 and a first guide profile 1. Thesocket outlet profile may be provided with different openings. It ispreferred that openings are stamped with Ø63 to match the standarddimensions for junction boxes.

It will be possible to mount a total of three openings above each otherbetween each of the mounting guide profiles 6 which form the horizontalprofiles, respectively the first guide profile 1 which forms thetransversal roof metal profile. It should be noted that the socketoutlet profile 35 can be displaced in horizontal direction. The socketoutlet profile 35 is mounted without the use of tools. At each end, thesocket outlet profile has a folded tab 36. As can be seen from FIG. 11,this tab will be used for engagement in a cavity in the mounting guideprofile 6 and will be folded around a central part of this Z-shapedprofile. This fixes the socket outlet profile 35. Following thetemporary mounting, the socket outlet profile can be nailed or rivetedfor a permanent fixing.

FIGS. 12 and 13 show how a window opening 19 or door opening is formedin a building structure. FIGS. 14 and 15 show the details of this windowopening.

It can be seen here that on the intermediate metal profile 15, a firstangle bracket 37 is fixed. To this, a horizontal frame profile 38 isfixed. The frame profile is mounted at an angle profile 37 at each end,the angle profile having a resiliently springy tab 28 corresponding tothe tab shown in FIGS. 5 and 6. The resiliently springy tab 28cooperates with a hole 39, which is punched in the horizontal frameprofile 38 at the end of this frame profile 38. However, otherconnection systems that the tab system can obviously be used.

Between two horizontal frame profiles 38, at least one vertical frameprofile 40 is provided for delimitation of a window opening or dooropening, which has a smaller width than the distance between twosubsequent intermediate metal profiles 15 which constitute the posts ofthe wall structure.

On the horizontal frame profile 38, as shown in FIG. 15, a second anglebracket 41 is mounted. This is placed displaceably in the longitudinaldirection of the horizontal frame profile 38. The angle bracket has afirst flange 42 for engagement with the underside of the frame profileand an intermediate flange part 43 which is in engagement against theside of the frame profile 38 as well as a third flange part 44 which isdesigned to abut the upper side of a frame profile, respectively theunderside of a frame profile, depending on whether the frame profile isplaced at the upper or lower end of a vertical frame profile 40. In thethird flange part 44 is a folded part 45, wherein an opening 46 isprovided. The opening 46 serves for cooperation with a resilient tab 28from the vertical frame profile 40. The second angle bracket can bedisplace to a desired position which depends on the width of the windowopening that is desired to be established.

The first angle bracket 37 can be displaced in the height directionalong the intermediate metal profile 15, so that the horizontal frameprofile 38 is placed at a desired height.

Following the temporary fixing, the elements can be mutually fixedpermanently by nailing with a gas-powered gun, riveting or by anotherpermanent fixing. However in another embodiment other connection typescould be used e.g. connecting directly by means of connection means andthus without the use of angle bracket.

FIG. 16 shows details of the roof structure 18. As can be seen from FIG.1, the structure comprises two lattice girders 48. Each lattice girderis formed from two opposite fourth guide profiles 49, in between whichfifth guide profiles 50 are mounted to form the lattice structure. Thelattice girder is mounted on the transversal foundation metal profile 13using a pole plate 51. The pole plate 51 is formed by a folded plateprofile 52, so that a side flange is formed on each side of the latticegirder 48, and a bottom flange that can be fixed to the transversalfoundation metal profile.

FIGS. 17 and 18 show the structure of a pitched roof 18, wherein the twolattice girders 48 are mounted using two seventh guide profiles 53mounted on each side of the lattice beams. As shown in FIG. 18 theseventh guide profiles are mounted by nailing using a gas-powered gun,riveting or another permanent joining on the two adjoining latticegirders. The two seventh guide profiles are identical.

FIGS. 19 and 20 show a sixth guide profile 54 used as bracing for thelattice beams 48 in the roof structure. In the sixth guide profile 54,openings 55 are provided with a well-defined mutual distance. Hereby,the lattice beams are positioned correctly in the roof structure inrelation to each other. The sixth guide profiles 54 thus act asrafters/struts.

FIG. 21 shows that the lattice beams are mounted on the pole plate 51,so that they are extended beyond the pole plate. This forms an overhang56 for the building. At the outer end of the lattice beams 48, aconnection profile 57 is provided. This allows for mounting of coveringelements, such as fascia boards or similar on the overhang 56.

FIG. 22 illustrates a building, wherein the roof structure is made withunilateral slope. It can thus be seen that the lattice beams 48 areplaced under an angle in relation to horizontal. Alternatively, thebuilding may be provided with a flat roof, and the lattice beams 48 willthen be placed horizontally on top of the transversal foundation metalprofile 13.

When a roof structure is placed, a reinforcement profile may be placedat the top of the external wall. This reinforcement profile may be aC-shaped profile, which ensures an upper side that is level with theupper side of the inner wall. Such a C-profile 58 is illustrated in FIG.23. Here, it can be seen that at each end of the C-profile, twojuxtaposed resiliently springy tabs 28 are provided, corresponding tothose shown in FIGS. 5 and 6.

FIG. 24 shows the fifth guide profile 50 which can be used in thelattice girder. By providing the beam with incisions 60 and lateralperforations 61, it is possible to make a zig-zag folding of the guideprofile 50 so that it can be placed inside the opposite guide profiles49 of the lattice girder structure.

FIG. 25 shows the transversal foundation metal profile 14, wherein tabs24 are provided with mutual spacing.

FIG. 26 discloses a wall section wherein the metal profiles 9, 13, 14,15 comprise identification means 66.

In this embodiment a digital representation of the building 11 is firstconstructed in a computer program such as a CAD program. From these CADinformation the different metal profiles 9, 13, 14, 15 aremanufactured—or at least cut to length—in an automated process.Substantially at the same time these metal profiles 9, 13, 14, 15 areprovided with identification means 66 so that each type of metal profile9, 13, 14, 15 can be uniquely identified from the identification means66. In this embodiment the identification means 66 are letters A, B, Cand D written on the profiles by an inject printer. However numerousother identification means 66 could be used for this purpose.

All the metal profiles 9, 13, 14, 15—forming the entire building 11—orat least forming an entire exterior wall 17 will be deliveredunassembled to the erection site, where the metal profiles 9, 13, 14, 15can be correctly assembled using an assembly plan showing how theuniquely marked metal profiles 9, 13, 14, 15 shall be assembled. Thisapproach severely reduces transportation cost in that only smallpackages of metal profiles 9, 13, 14, 15 has to be shipped instead ofcomplete buildings or large building modules. And given theidentification means 66 the wall 17 and the building 11 can still beassembled quickly.

After assembly of the entire exterior wall 17—and most likely the entirebuilding—inner sheathing 63 and outer sheathing 62 is provided whereafter insulation material will be injected into the walls in most cases.

The invention has been exemplified above with reference to specificexamples of inner walls 20, outer walls 21, metal profiles 9, 13, 14,15, 16 and other. However, it should be understood that the invention isnot limited to the particular examples described above but may bedesigned and altered in a multitude of varieties within the scope of theinvention as specified in the claims.

LIST

-   1.-   2. Vapour seal above the foundation-   3. Insulation between the outer and inner foundation-   4. Foundation block-   5. Facade cladding-   6. Mounting guide profile-   7. Power board-   8. Wall-   9. Strut-   10. Vapour barrier-   11. Building-   12. Foundation-   13. Transversal roof metal profile-   14. Transversal foundation metal profile-   15. Intermediate metal profile-   16. Horizontal profile-   17. Exterior wall-   18. Roof structure-   19. Window opening-   20. Inner wall-   21. Outer wall-   22. Distance profile-   23. Fire-resistant layer-   24. Tab-   25. Vertical flange-   26. Horizontal flange-   27. Hole in the tab-   28. Resiliently spring tab-   29, 30. Flange-   31. Central flange-   32. Central part-   33. Insulation material-   34. Cavity-   35. Socket outlet profile-   36. Folded tab-   37. First angle bracket-   38. Horizontal frame profile-   39. Hole in the horizontal frame profile-   40. Vertical frame profile-   41. Second angle bracket-   42. First flange-   43. Intermediate flange part-   44. Third flange part-   45. Folded part-   46. Opening-   47. Folding line-   48. Lattice beam-   49. Fourth guide profile-   50. Fifth guide profile-   51. Pole plate-   52. Folded plate profile-   53. Seventh guide profile-   54. Sixth guide profile-   55. Sixth guide profile opening-   56. Overhang-   57. Connection profile-   58. C-profile-   59. Inside surface of inner wall-   60. Incisions-   61. Lateral perforations-   62. Outer sheathing-   63. Inner sheathing-   64. Outside surface of outer wall-   65. Connection means-   66. Identification means-   67. Gap

1. An exterior wall for a building, said exterior wall comprising: aninner wall including a load-bearing structure formed by a transversalroof metal profile and a transversal foundation metal profile betweenwhich a number of intermediate metal profiles extend, and wherein aninside surface of said inner wall is provided with inner sheathing, andan outer wall including a load-bearing structure formed by a transversalroof metal profile and a transversal foundation metal profile betweenwhich a number of intermediate metal profiles extend, and wherein anoutside surface of said outer wall is provided with outer sheathing,wherein said inner wall and said outer wall are mutually fixed at saidtransversal metal roof profiles and said transversal metal foundationprofiles so that a cavity is formed between said inner wall and saidouter wall.
 2. The exterior wall according to claim 1, wherein saidinner sheathing and/or said outer sheathing comprises a vapour barrier.3. The exterior wall according to claim 1, wherein said inner sheathingand/or said outer sheathing comprises a fire-resistant layer.
 4. Theexterior wall (17) according to claim 1, wherein said outer sheathingcomprises façade cladding. 5-6. (canceled)
 7. The exterior wallaccording to claim 1, wherein thermal insulation means is arrangedinside said cavity.
 8. The exterior wall according to claim 1, whereinthermal insulation means is arranged between said metal profiles of saidinner wall and between said metal profiles of said outer wall.
 9. Theexterior wall according to claim 1, wherein each metal profile of saidinner wall and said outer wall comprises identification means enablingthat each unique metal profile can be uniquely identified. 10.(canceled)
 11. The exterior wall according to claim 1, wherein amajority of said intermediate metal profiles of said inner wall isdisplaced in relation to a majority of said intermediate metal profilesof said outer wall as seen in a direction perpendicular to said innerwall.
 12. The exterior wall according to claim 1, wherein saidtransversal roof metal profile of said inner wall is parallel with saidtransversal roof metal profile of said outer wall and wherein saidtransversal foundation metal profile of said inner wall is parallel withsaid transversal foundation metal profile of said outer wall.
 13. Theexterior wall according to claim 1, wherein said transversal roof metalprofile of said inner wall is parallel with said transversal foundationmetal profile of said inner wall and wherein said transversal roof metalprofile of said outer wall is parallel with said transversal foundationmetal profile of said outer wall.
 14. The exterior wall according toclaim 1, wherein said intermediate metal profiles extends perpendicularin relation to said transversal roof metal profiles and said transversalfoundation metal profiles.
 15. A method for constructing an exteriorwall of a building, said method comprising the steps of: assembling anumber of prefabricated metal profiles according to a predefined plan toform an inner wall of said exterior wall of said building, assembling anumber of prefabricated metal profiles according to a predefined plan toform an outer wall of said exterior wall of said building, mutuallyfixing said inner wall and said outer wall in relation to each other ata foundation of said building and at a roof of said building so that acavity is formed between said inner wall and said outer wall.
 16. Themethod according to claim 12, wherein said method further comprises thestep of substantially covering an inside surface of said inner wall withan inner sheathing.
 17. The method according to claim 12, wherein saidmethod further comprises the step of substantially covering an outsidesurface of said outer wall with an outer sheathing.
 18. The methodaccording to claim 12, wherein said method further comprises the step ofarranging thermal insulation means inside said cavity.
 19. The methodaccording to claim 12, wherein said method further comprises the step ofarranging thermal insulation means between said metal profiles of saidinner wall and between said metal profiles of said outer wall.
 20. Themethod according to claim 12, wherein said method further comprises thestep of providing identification means to said metal profiles.
 21. Themethod according to claim 12, wherein said method is a method forconstructing an exterior wall according to any of claims 1-114.
 22. Thesystem for construction of a building erected on a foundation, and whichcomprises a transversal roof metal profile, a transversal foundationmetal profile and intermediate metal profiles between transversal roofmetal profile and transversal foundation metal profile, horizontalprofiles as well as a roof structure, the system comprising: thetransversal roof metal profile and the transversal foundation metalprofile comprise a first guide profile for an inner wall and a firstguide profile for an outer wall in a wall structure as well as a spacingelement located between these first guide profiles, which first guideprofile comprises an angle profile having a horizontal flange in use anda vertical flange in use, wherein in the horizontal flange with apredefined mutual distance, first tabs are provided which are folded soas to be located under an angle in relation to the horizontal flange,and which each comprise a hole, the transversal foundation metal profilecan act as a wall plate in a floor separation or a wall plate to supportthe roof structure, each post comprises a intermediate metal profilelocated between the first guide profiles in the inner wall or the outerwall at a position in line with the first tabs, which intermediate metalprofile comprises two opposite flanges located in parallel planes, whichare mutually connected by a central flange, wherein at each end of thecentral flange of the intermediate metal profile, a second tab isprovided, which is resilient in relation to the central flange, andwhich are each adapted for resilient engagement in the hole in the firsttab, each horizontal profile comprises a mounting guide profile whichcomprises two opposite flanges located in parallel planes, which aremutually connected by a central flange, the first of the oppositeflanges being adapted for mounting on the posts, and the second of theopposite flanges being adapted for mounting of inner cladding or facadecladding of the inner wall, respectively the outer wall, and the roofstructure comprises a lattice girder formed by two opposite fourth guideprofiles, between which fifth guide profiles are mounted to form thelattice structure.
 23. A system according to claim 19, wherein posts inthe inner wall and the outer wall are displaced in relation to eachother, and that the posts are preferably mounted in every second of thefirst tabs in the first guide profiles. 24-34. (canceled)